Honda XR200R 1984-1985, XL250, XR250 1978-2000, XL350, XR350 1983-1985 Repair Manual

• Honda XR200R, 1984-1985*
• Honda XL250S, 1978-1981
• Honda XL250R, 1982-1987
• Honda XR250, 1979-1980
• Honda XR250R, 1981-1982, 1984-2000
• Honda XR250L, 1991-1996
• Honda XL350R, 1984-1985
• Honda XR350R, 1983-1985

BREAK-IN PROCEDURE

If the rings were replaced, a new piston installed, the cylinder rebored or honed or major lower end work performed, the engine should be broken in just a though it were new. The performance and service life of the engine depends greatly on a careful and sensible break-in.

For the first 5-10 hours of operation, no more than one-third throttle should be used and speed should be varied as much as possible within the one-third throttle limit. Prolonged steady running at one speed, no matter how moderate, is to be avoided as well as hard acceleration.

Following the first 5-10 hours of operation more throttle should not be used until the bike has run for 100 hours and then it should be limited to short bursts of speed until 150 hours have been logged.

During this period, oil consumption will be higher than normal. It is therefore important to frequently check and correct oil level.

At no time, during the break-in or later, should the oil level be allowed to drop below the bottom line on the dipstick; if the oil level is low, the oil will become overheated resulting in insufficient lubrication and increased wear.

The bike is equipped with a small fuel filter screen in the fuel shutoff valve. Considering the dirt and residue that is often found in today's gasoline, it is good idea to install an inline fuel filter to keep the carburetor clean.

A good quality inline fuel filter (A.C. part No. GF453 or equivalent) is available at most auto and motorcycle supply stores. Just cut the fuel line from the fuel tank to the carburetor and install the filter.

Cut out a section of the fuel line the length of the filter so the fuel line does not kink and restrict fuel flow. Insert the fuel filter and make sure the fuel line is secured to the filter at each end.

• Quick Reference Data
• General Information
• Troubleshooting
• Lubrication, Maintenance and Tune-up
• 1978-1983 250cc Engine
• 200 thru 350cc RFVC Engine
• Clutch and Transmission
• Fuel and Exhaust Systems
• Front Suspension and Steering
• Rear Suspension
• Brakes
• Suspension Adjustment
• Wiring Diagrams